Generating Quality
Since
7925
POWR-PAK"
/
EGSA
ELEC-
WINPOWER CORPORATION
NEWTQN,
IOWA
50208
U.S.A.
PHONE:
(515) 792-1301
/CABLE: WINPOWER
/
TELEX
11:
910-520-1557
Printed
in
U.S.A.
INTRODUCTION
This manual covers the safety, operating and maintenance instructions for the
WINPOWER line of air-cooled generator
sets.
Included as a part of the package
is
a parts
list
and wiring diagram covering the particular model you have pur-
chased. The engine manufacturer's manual
is
also furnished with the set and
gives the necessary operating and maintenance information for the engine.
GENERAL
The engine generator
sets
covered by this manual are of the single bearing
type. The rotating member of the generator
is
mounted on a tapered extension
of the engine crankshaft.
All
sets
have been thoroughly tested at the factory. The normal carburetor
and engine speed,adjustments have been made.
The
set
should
be
carefully inspected on delivery for evidence of possible
shipping damage. If damage has occurred, a notation should
be
made on the
freight bill and you should file
a
claim, if necessary. If the damage appears
to
be of a major nature, the
set
should not be operated until the fault has
been corrected.
The model number and the serial number of the
set
must be given when contacting
the
dealer
or the factory.
ELECTRICAL DESCRIPTION
\
The generators used in the WINPOWER line of air-cooled engine generator
sets
are
revolving armature type.
The
static,
or
electronic excitation system, uses rectifiers to change part of
the output of the
AC
generator
to
DC
for excitation of the field. On
most
models using
static
excitation, this system
is
extended
still
further by using
current feedback through rectifiers in order to obtain increasing field strength
with load increase
to
give
better
voltage regulation.
ENGINE
STARTING
The engine manual should be followed in regards to operation. The engine
crankcase must be filled with an oil recommended by the engine manufacturer.
The fuel should
be
regular grade automotive gasoline. When filling the tank,
allow for fuel expansion. Never fill tank when engine is running.
The carburetor choke should
be
adjusted as required by temperature conditions.
When starting the generator, the operator should assume a stable stance to
prevent injury in the event of engine kickback. Pull the start rope with a
quick, smooth pull to crank the engine.
Be
sure to pull the rope completely
through until it clears the starting pulley. After the engine starts, return
choke to its normal position. In cold temperatures it may
be
necessary to
keep the choke in the choke position longer;
HIGH MOISTLIRE CONDITIONS
The use of electrical equipent under extremely wet conditions should
be
avoided
.
EXHAUST
Generator units must
be
operated
in
a
well ventilated area
to
provide adequate
cooling air for the engine and proper discharge
of
exhaust fumes.
STABILITY
Generator units should
be
placed on a solid level surfhce for proper engine
operation. If there is
any
indication that the unit may shift during opera-
tion, the use of tie downs is reconawnded.
EXTENSION CORDS
The proper selection of
an
extension cord is necessary for optimum tool opera-
tion. Consult the following chart for proper wire size to carry the required
load current. Voltage drops due to the extension cord should not exceed five
pol ts
.
VOLTAGE
DROP
@
MAXIMUM
AMPS
FOR
WIRe SIZE GIVEN WIRE
1;ENGTHS
AWG
-
MAX.
AMPS
25
'
-
50
'
-
75
'
-
100'
-
MAINTENANCE
ENGINE
Refer
to
engine manual.
GENERATOR
Check brush lengths after 500 hours of running and every 100 hours thereafter.
If brush length
is
less
than 1/2", the brush should be replaced with a new one.
SANDING BRUSHES
It
is
important that the brushes make good
contact with the
collector
rings. When
rit
side
installing
a
new
set
of brushes, they of
should be sanded in by using 00 sandpaper. sandpaper
'collector
ring
The sandpaper should be pulled in the direction of rotation. When pulled in
the opposite direction
to
start
a new stroke, the brush should be raised.
Continue the sanding until the brushes are fully seated.
Do
not use emery -cloth.
The
collector
rings should be cleaned if dirty.
Dirt
and the moisture
it
will
hold are detrimental
to
generators. If dust and
dirt accumulate, the generator should be cleaned periodically.
THE FOLLOWING SERVICE PROCEDURES SHOULD BE PERFORMED
BY
AUTORIZED WINPOWER.
L
SERVICE CENTERS OR OTHER QUALIFIED PERSONNEL.
TESTING FOR OPEN CIRCUITS
TESTING
The most likely place for an open circuit
to
occur
is
the shunt field circuit.
The shunt field
is
connected
to
the rectifier output. One end of the shunt
field should be disconnected. An ohmmeter reading should be taken between the
disconnected end the other end
to
determine continuity. If no reading
is
obtained there
is
an open circuit,
Its
exact location should then be determined
and the open circuit should be repaired. The output leads should be checked for
continuity.
RESTORING RESIDUAL MAGNETISM
PROCEDURE:
It
can be done by applying DC voltage
(6-24
volts)
across
the terminals of the
shunt field. Care must be taken that the polarity
is
correct. Incorrect
polarity
will
destroy the diodes in the rectifier bridge if a limiting resistor
is
not used.
TESTING RECTIFIERS
AND
DIODES
DEFINITIONS
A
diode
is
a single rectifying element represented graphically as shown below:
-
When a diode
is
used alone such
as
in half wave rectification
it
can also be
called a rectifier. Two diodes are used in full wave rectification as shown:
Four diodes are used in a single phase rectifier bridge as shown:
TESTING
An ohmeter
is
required for testing
a
diode or rectifier assembly.
It
is
neces-
sary
to
remove the leads going
to
the rectifier for testing
it.
A
single diode
will
show a very high resitance in one direction and low resistance in the
other direction,
@-
a
-
+
-
Low Reading Very High Reading
A
shorted diode
will
have a low reading in both directions, An open diode
will
have a high reading in
both
directions. Each diode in an assembly can
be
tested
as shown below:
AC
Low Reading Very High Reading
This reading has
te
be repeated on every diode.
If
the rectifier assembly
is
a molded assembly, test as follows:
Using a volt-amp-ohm meter
(multi
meter), check the rectifier assembly
kn
the following sequence:
Check Between
For purposes of order
in
checking,
consider one
AC
terminal as
#1,
the other as
#2.
Expected
Resistance
Reading
+
Meter lead on
+
terminal
-
meter lead on
AC
#1
High
+
Meter lead on
+
terminal
-
meter lead on
AC
#2
High
+
Meter lead on
-
terminal
-
meter lead on
AC
#1
Low
+
Meter lead on
-
terminal
-
meter lead on
AC
#2
Low
+
Meter lead on
AC
#1
-
meter lead on
+
terminal Low
+
Meter lead on
AC
#l
-
meter lead on
-
terminal High
+
Meter lead on
AC
#2
-
meter lead on
+
terminal Low
+
Meter lead on
AC
#2
-
meter lead on
-
terminal High
If
any readings do not comply
with
the above chart, the rectifier assembly
is
defective and should be replaced.
TROUBLE SHOOTING CHART
-
structions for testing
rectifier bridges).
Poor brush contact Free brush
if
stuck. Re-
(brush can be stuck in place with new brush
if
worn. Replace brush spring
Open circuit (see in- Complete circuit
if
in
structions for testing external wiring.
of open circuits)
.
Shorted armature coil s Rep1 ace armature
in revolving armature
Engine speed too low.
correct value.
Replace diode or rectifier
field bridge (see in-
structions for testing
rectifier bridge).
speed drops off See engine manual.
High output voltage Excessive engine speed
Excessive generator Over1 oad on generator. Reduce load.
Clean inlets and outlets.
Arcing at brushes Brushes not seated See instructions for
sanding brushes.
ECON-0-MIZER
MAGNET ADJUSTMENT INSTRUCTIONS
1.
Place Economizer switch
in
off position, start engine.
L
2.
Manually push Economizer arm on carburetor
up
or down
to reach an idle speed, adjust engine idle set screw
cw to reach 50-60 volts
AC
at 120 volt receptical.
3.
Stop engine, adjust magnet up or down so that
it
just
touches the Economizer arm. While holding the arm
in
idle position, tighten magnet into
this
position.
4.
Turn idle set screw one-half
turn
ccw so that screw
does not touch stop on carburetor when arm
is
against
magnet. Adjustment
is
complete.
5. If Economizer
will
not hold at idle, off load and switch
turned on', adjust the magnet farther from the carburetor
arm.
Parts Drawing IE-9616-3
-
'Recommended Parts for Stock
.
I--
I
(A)
Was
EC-11315 Mar.
7,
1985
GRS
REF,
N.S.
1
*2
3
4
"5
*5A
.
6
'
7
8
"9
"1
*lo
1
12
*I
3
NOS.
*N.S,
"1
4
*I5 *I
6
*I7
18
*I
9
"2
1
**'
22
23
"24
25
NOS.
NOS,
N.S,
PART DESCRIPTION
Engine BAS
(A)
Drive End Bell
Armature Assembly
Field Frame Assembly
Field Frame
Field Coil Shunt
Field Coil Series
Field Pole Assembly
Coil Shield
Stud
Bearing
Fan
Armaturestud
Brush Gear Assembly
Rectifier Assembly-Shunt
Heat Sink
Rectifier Assembly-Series
Brush
Brush Spring
End Hood
Receptacle (5-15~)
Not Applicable
Isolation Mount
Switch
Economizer Module
Collar
Pivot Arm
.
.
Magnet with Cover
Mounting Plate
Circuit
Breaker
15
Amp
Carrying Frame
.4
Wiring Dia, IE-11822-1
MODEL
~~OOBP/IC
Wiring Dia.IE-11821-1
'
TYPE 2
PART NO.
,
#
-.--
--
EC-11315-5
1-873
G-6359-7
G-6018-8
-
G-6017-2
H-1236
ti-1
236-1
G-5592-2.
J-662
S-6657
D-5
A-798- 1
S-8610-53
G-6016-2
EE-2188-1
A-788
EE-2214
REQgD
----
----
---
1
1
1
1
1
2
2
2
4
3
1
1
1
1
'I
1
1
1
1
1
1
1
1
1
MODEL
~~OOBEP/IC
Y-117
L-24
S-7589-
16
-
EE-323-5
W-207
Not Appl,
Not Appl,
Not Appl,
Not Appl,
Not Appl,
Not Appl,
EE-1885
G-7569
TYPE
2
PART NO,
-------
REQ'D
----
-----
2
2
1
1
3
2
2
'I
S-7589-
17
*
EE-168-1
G-7436
S-6744
S-6741
G-7469
5-6737
DATE
OWNER'S SERVICE RECORD
CONSULT ENGINE MANUAL FOR SUGGESTED
MAINTENANCE AND SERVICE INTERVALS
CONSULT GENERATOR SET OWNER'S MANUAL
FOR GENERATOR SERVICE AND MAINTENANCE
GENERATOR SET: ENGINE:
Model No. Type Model
Serial No. Serial No.
Purchased From
Placed in Service
/
